2001 CHRYSLER VOYAGER relay

TEST ACTION APPLICABILITY
8NOTE: Ensure the IPM C4 harness connector is connected to the IPM.
Turn the ignition off.
Disconnect the PCM harness connector.
Measure the resistance of the ASD Relay Output circuit between the IPM and the
PCM harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Replace and program the Powertrain Control Module in accor-
dance with the Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Replace the IPM Fuse & Relay Center.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
9WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
NOTE: The conditions that set the DTC are not present at this time. The
following list may help in identifying the intermittent condition.
With the engine running at normal operating temperature, monitor the DRB
parameters related to the DTC while wiggling the wiring harness. Check for the
engine stumble, stall or quite running.
Refer to any Technical Service Bulletins (TSB) that may apply.
Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or
partially broken wires.
Visually inspect the related wiring harness connectors. Look for broken, bent, pushed
out, or corroded terminals.
Were any of the above conditions present?All
Ye s®Repair as necessary
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Test Complete.
200
DRIVEABILITY - GAS
P1389-NO ASD RELAY OUTPUT VOLTAGE AT PCM ÐContinued

Symptom:
P1491-RAD FAN CONTROL RELAY CIRCUIT
When Monitored and Set Condition:
P1491-RAD FAN CONTROL RELAY CIRCUIT
When Monitored: With the ignition on. Battery voltage greater than 10 volts.
Set Condition: An open or shorted circuit is detected in the radiator fan relay control
circuit.
POSSIBLE CAUSES
RADIATOR FAN RELAY INTERMITTENT OPERATION
INTERMITTENT CONDITION
GROUND CIRCUIT
FUSED B+ OUTPUT CIRCUIT
POWERTRAIN CONTROL MODULE
RADIATOR FAN RELAY CONTROL CIRCUIT SHORT TO GROUND
RADIATOR FAN RELAY CONTROL CIRCUIT OPEN (IPM)
RADIATOR FAN RELAY CONTROL CIRCUIT OPEN (PCM)
RADIATOR FAN RELAY CONTROL CIRCUIT SHORTED TO GROUND (IPM)
RADIATOR FAN RELAY CONTROL CIRCUIT SHORT TO GROUND (PCM)
INTELLIGENT POWER MODULE (OPEN)
INTELLIGENT POWER MODULE (SHORTED)
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRBIIIt, actuate the Radiator Fan Relay.
Are both Radiator Fan operating?All
Ye s®Go To 2
No®Go To 4
2 Turn the ignition on.
With the DRBIIIt, actuate the Radiator Fan Relay.
Wiggle the wiring harness from the Radiator Fan Relay to the PCM while the relay
is actuating.
Did the Radiator Fan Relay stop when wiggling the wiring harness?All
Ye s®Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 3
210
DRIVEABILITY - GAS

TEST ACTION APPLICABILITY
3WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE
PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
NOTE: The conditions that set the DTC are not present at this time. The
following list may help in identifying the intermittent condition.
With the engine running at normal operating temperature, monitor the DRB
parameters related to the DTC while wiggling the wiring harness. Look for param-
eter values to change and/or a DTC to set.
Review the DRB Freeze Frame information. If possible, try to duplicate the
conditions under which the DTC was set.
Refer to any Technical Service Bulletins (TSB) that may apply.
Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or
partially broken wires.
Visually inspect the related wiring harness connectors. Look for broken, bent, pushed
out, or corroded terminals.
Were any of the above conditions present?All
Ye s®Repair as necessary
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Test Complete.
4 Turn the ignition off.
Disconnect the Radiator Fan Relay harness connector.
Using a 12-volt test light connected to 12-volts, probe the Ground circuit in the
Radiator Fan Relay harness connector.
Does the test light illuminate?All
Ye s®Go To 5
No®Repair the Ground circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
5NOTE: Inspect the Radiator Fan fuse located in the IPM.
Turn the ignition off.
Disconnect the Radiator Fan Relay harness connector.
Measure the voltage of the Fused B+ Output circuit in the Radiator Fan Relay
harness connector.
Is the voltage above 11.0 volts?All
Ye s®Go To 6
No®Repair the Fused B+ circuit. Check and replace any open fuses.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
6NOTE: Ensure the Radiator Fan Relay harness connector is connected.
Turn the ignition off.
Disconnect the PCM harness connector.
Turn the ignition on.
Using a jumper wire, momentarily jumper the Radiator Fan Relay Control circuit to
ground.
Did the Radiator Fans operate?All
Ye s®Replace and program the Powertrain Control Module in accor-
dance with the Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 7
211
DRIVEABILITY - GAS
P1491-RAD FAN CONTROL RELAY CIRCUIT ÐContinued

TEST ACTION APPLICABILITY
7 Turn the ignition off.
Disconnect the Radiator Fan Relay harness connector.
Disconnect the PCM harness connector.
Measure the resistance of the Radiator Fan Relay Control circuit between the
Radiator Fan Relay harness connector and the PCM harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 8
No®Go To 11
8 Turn the ignition off.
Disconnect the Radiator Fan Relay harness connector.
Disconnect the PCM harness connector.
Measure the resistance of the Radiator Fan Relay Control circuit in the Radiator Fan
Relay harness connector to ground.
Is the resistance below 5.0 ohms?All
Ye s®Go To 9
No®Replace Radiator Fan Relay.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
9 Turn the ignition off.
Disconnect the Radiator Fan Relay harness connector.
Disconnect the IPM C2 harness connector.
Measure the resistance of the Radiator Fan Relay Control circuit in the Radiator Fan
Relay harness connector to ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the Radiator Fan Relay Control circuit for a short to
ground between the Radiator Fan Relay harness connector and
the IPM harness connector.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Go To 10
10 Turn the ignition off.
Disconnect the PCM harness connector.
Disconnect the IPM C3 harness connector.
Measure the resistance of the Radiator Fan Relay Control circuit in the PCM harness
connector to ground.
Is the resistance below 5.0 ohms?All
Ye s®Repair the Radiator Fan Relay Control circuit for a short to
ground between PCM harness connector and the IPM harness
connector.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Replace the IPM Fuse & Relay Center.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
212
DRIVEABILITY - GAS
P1491-RAD FAN CONTROL RELAY CIRCUIT ÐContinued

TEST ACTION APPLICABILITY
11 Turn the ignition off.
Disconnect the Radiator Fan Relay harness connector.
Disconnect the IPM C2 harness connector.
Measure the resistance of the Radiator Fan Relay Control circuit between the IPM
harness connector and the Radiator Fan Relay harness connector.
Is the resistance below 5.0 ohms.All
Ye s®Go To 12
No®Repair the Radiator Fan Relay Control circuit for an open
between the Radiator Fan Relay harness connector and the IPM
harness connector.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
12 Turn the ignition off.
Disconnect the PCM harness connector.
Disconnect the IPM C3 harness connector.
Measure the resistance of the Radiator Fan Relay Control circuit between the IPM
harness connector and the PCM harness connector.
Is the resistance below 5.0 ohms.All
Ye s®Replace the IPM Fuse & Relay Center.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
No®Repair the Radiator Fan Relay Control circuit for an open
between PCM harness connector and the IPM harness connector.
Perform POWERTRAIN VERIFICATION TEST VER - 5.
213
DRIVEABILITY - GAS
P1491-RAD FAN CONTROL RELAY CIRCUIT ÐContinued

Symptom:
*CHECKING FUEL DELIVERY
POSSIBLE CAUSES
FUEL PUMP RELAY
FUEL PRESSURE OUT OF SPECS
RESTRICTED FUEL SUPPLY LINE
FUEL PUMP INLET STRAINER PLUGGED
FUEL PUMP MODULE
FUEL PUMP CAPACITY (VOLUME) OUT OF SPECS
FUEL PUMP RELAY FUSED B+ CIRCUIT
FUEL PUMP RELAY OUTPUT CIRCUIT OPEN
FUEL PUMP GROUND CIRCUIT OPEN/HIGH RESISTANCE
IPM FUSE & RELAY CENTER
FUEL PUMP MODULE
TEST ACTION APPLICABILITY
1NOTE: Inspect the Fuel Pump Relay fuse located in the IPM. If the Fuel
Pump Relay fuse is open, repair the cause of the open first before continu-
ing. Inspect the Fuel Pump Relay Output circuit for a short to ground for
the cause of the open fuse.
Turn the ignition on.
With the DRBIIIt, actuate the ASD Fuel System test.
Note: It may be necessary to use a mechanics stethoscope in the next step.
Listen for fuel pump operation at the fuel tank.
Does the Fuel Pump operate?All
Ye s®Go To 2
No®Go To 6
Caution: Stop All Actuations.
227
DRIVEABILITY - GAS

TEST ACTION APPLICABILITY
5Note: The fuel pressure must be within specification before continuing.
Turn the ignition off.
WARNING: The fuel system is under a constant pressure even with the
engine off. Before testing or servicing any fuel system hose, fitting or line,
the fuel system pressure must be released.
Disconnect the fuel supply line at the fuel rail.
Connect fuel line adapter #6539(5/169) or #6631(3/89) to the disconnected fuel supply
line. Insert the other end of the adapter into a graduated container.
Caution: Do not operate the fuel pump for more than 7 seconds in the next
step. Fuel pump module reservoir may run empty and damage to the fuel
pump will result.
Note: Specification: A good fuel pump will deliver at least 1/4 liter (1/2 pint)
of fuel in 7 seconds.
Turn the ignition on.
With the DRBIIIt, actuate the ASD Fuel System test for 7 seconds.
Is the fuel pump capacity within specification?All
Ye s®Test Complete.
No®Check for a kinked/damaged fuel supply line between the fuel
tank and fuel rail. If OK, replace the fuel pump module.
Perform POWERTRAIN VERIFICATION TEST VER-1.
Caution: Stop All Actuations.
6 Turn the ignition off.
Disconnect the fuel pump module harness connector.
Turn the ignition on.
With the DRBIIIt, actuate the ASD Fuel System test.
Using a 12 volt test light connected to ground, probe the Fuel Pump Relay Output
circuit at the Fuel Pump Module harness connector.
Does the test light illuminate brightly?All
Ye s®Go To 7
No®Go To 9
Caution: Stop All Actuations.
7 Turn the ignition off.
Disconnect the Fuel Pump Module harness connector.
Note: Check connectors - It is critical that the connector is free from any
signs of corrosion or deformities - Clean/repair as necessary.
Using a test light connected to battery voltage, probe the Fuel Pump ground circuit
at the Fuel Pump Module harness connector.
Does the test light illuminate brightly?All
Ye s®Go To 8
No®Repair the open/high resistance in the fuel pump ground circuit.
Perform POWERTRAIN VERIFICATION TEST VER-1.
8 If there are no possible causes remaining, view repair. All
Repair
Replace the Fuel Pump Module.
Perform POWERTRAIN VERIFICATION TEST VER-1.
229
DRIVEABILITY - GAS
*CHECKING FUEL DELIVERY ÐContinued

TEST ACTION APPLICABILITY
9 Turn the ignition off.
Remove the Fuel Pump Relay from the IPM.
With a 12 volt test light connected to ground, probe the Fuel Pump Relay Fused B+
circuit at the IPM.
Does the test light illuminate?All
Ye s®Go To 10
No®Check for an open Fuel Pump fuse, repair cause of open. If OK,
replace the IPM Fuse & Relay Center.
Perform POWERTRAIN VERIFICATION TEST VER-1.
10 Turn the ignition off.
Disconnect the Fuel Pump Module harness connector.
Disconnect the IPM C8 harness connector.
Measure the resistance of the Fuel Pump Relay Output circuit from between the IPM
harness connector and the Fuel Pump Module harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 11
No®Repair the Fuel Pump Relay Output circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER-1.
11NOTE: Ensure all IPM harness connectors are connected.
Turn the ignition off.
Disconnect the Fuel Pump Module harness connector.
Remove the Fuel Pump Relay from the IPM.
Measure the resistance of the Fuel Pump Relay Output circuit between the IPM and
the Fuel Pump Module harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Replace the Fuel Pump Relay.
Perform POWERTRAIN VERIFICATION TEST VER-1.
No®Replace the IPM Fused & Relay Center.
Perform POWERTRAIN VERIFICATION TEST VER-1.
230
DRIVEABILITY - GAS
*CHECKING FUEL DELIVERY ÐContinued